Electronic cigarette with liquid reservoir

ABSTRACT

An electronic cigarette including an housing that has a mouthpiece with an aerosol outlet, and an atomizer disposed within an atomizing chamber. The atomizer selectively generates an aerosol of the liquid in response to suction pressure at the aerosol outlet. The atomizing chamber has an air inlet, an atomizer outlet coupled to the aerosol outlet, and a first wick aperture. A liquid reservoir is disposed within the housing, which is sealably separated from the atomizing chamber. A wick disposed through the first wick aperture between the liquid reservoir and the atomizing chamber and it is configured to transfer the liquid by capillarity from the liquid reservoir to the atomizer.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to electronic cigarettes. Morespecifically, the present invention relates to an electronic cigarettewith an internal liquid reservoir.

Description of the Related Art

Electronic cigarettes have become increasingly popular in recent times.Electronic cigarettes emulate a tobacco cigarettes, but without thecombustion of tobacco during use. Rather than burning tobacco, a liquidis atomized within the electronic cigarette, which emulates the smokeproduced in a tobacco cigarette. The liquid may contain flavoring agentssuch as tobacco flavor, menthol, and others, to enhance the “smoking”experience of the electronic cigarette. Nicotine has been added to theatomization liquid in prior art electronic cigarettes. In certain priorart electronic cigarettes, a reserve of liquid is stored within thecigarette housing in a porous material, which is placed into contactwith an atomizing assembly such that the liquid can be graduallytransferred to the atomizing assembly during consumption. A replaceablecartridge with a liquid soaked porous material has been provided toenable consumers to replenish the supply of liquid as it is depletedduring use by replacing the cartridge. It should be appreciated that thestructural and electrical components in an electronic cigarette aredurable and outlast, by a long measure, the period of consumption forthe quantity of liquid provided in such a porous reservoir.

Consumers of electronic cigarettes are experienced at replacing theliquid reservoir cartridges as the liquid is depleted duringconsumption. In fact, it is common for consumers to carry sparecartridges so that they are readily available in the event their currentcartridge becomes depleted. In fact, this arrangement can becomesomewhat tedious after a period of use, and there is a general desire onthe marketplace to extend the duration of use between cartridge changes,or even the elimination of the need to ever change cartridges. Thus iscan be appreciated that there is a need in the art for an apparatus forincreasing the quantity of liquid stored within an electronic cigaretteand other means to reduce the frequency of replacing or addingadditional liquid during use.

SUMMARY OF THE INVENTION

The need in the art is addressed by the apparatus of the presentinvention. The present invention teaches an electronic cigaretteapparatus including an elongated housing that has a mouthpiece with anaerosol outlet, and an atomizer disposed within an atomizing chamber.The atomizer selectively generates an aerosol of the liquid in responseto suction pressure at the aerosol outlet. The atomizing chamber has anair inlet, an atomizer outlet coupled to the aerosol outlet, and a firstwick aperture. A liquid reservoir is disposed within the elongatedhousing, which is sealably separated from the atomizing chamber. A wickdisposed through the first wick aperture between the liquid reservoirand the atomizing chamber and it is configured to transfer the liquid bycapillarity from the liquid reservoir to the atomizer.

In a specific embodiment, the foregoing apparatus further includes aninlet vent formed on the exterior of the elongated housing that iscoupled to deliver air to the atomizing chamber air inlet. In arefinement to this embodiment, the inlet vent is coupled to theatomizing chamber air inlet by a conduit. In a further refinement, theconduit sealably passes through the liquid reservoir.

In a specific embodiment of the foregoing apparatus, the atomizer outletand the aerosol outlet are coupled together by a chimney. In arefinement to this embodiment, the chimney sealably passes through theliquid reservoir.

In a specific embodiment of the foregoing apparatus, the atomizer is aresistive heating element. In a refinement to this embodiment, the wickis partially engages the resistive heating element.

In a specific embodiment of the foregoing apparatus, the atomizer has atubular form defining an open central passage. In a refinement to thisembodiment, the wick passes through the open central passage.

In a specific embodiment of the foregoing apparatus, the atomizingchamber further includes a second wick aperture, and the apparatus isarranged such that a first end of the wick passes through the first wickaperture and a second end of the wick passes through the second wickaperture.

In a specific embodiment of the foregoing apparatus, the wick isfabricated as a bundle of heat resistant fibers. In a refinement to thisembodiment, the bundle of heat resistant fibers is fiberglass. Inanother refinement to this embodiment, the bundle of heat resistantfibers is fabricated from a material selected from; aramid,fluorocarbon, sulfide, melamine, polyimide, carbon, and glass.

In a specific embodiment of the foregoing apparatus, the liquidreservoir is formed as an annular cavity between the interior of theelongated housing and the atomizing chamber. In another specificembodiment of the foregoing apparatus, the liquid reservoir includes anexternal access opening, for enabling addition of liquid into the liquidreservoir. In a refinement to this embodiment, the external accessopening is a removable mouthpiece.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view drawing of an electronic cigaretteaccording to an illustrative embodiment of the present invention.

FIGS. 2a, 2b, and 2c are a tip end view, a side view, and mouthpiece endview, respectively, drawings of an electronic cigarette according to anillustrative embodiment of the present invention.

FIGS. 3a and 3b are side view drawings, respectively, of a cartridgeportion and a power supply portion of an electronic cigarette accordingto an illustrative embodiment of the present invention.

FIGS. 4a, 4b, and 4c are tip end view, side section view, and mouthpieceend view, respectively, drawings of an electronic cigarette according toan illustrative embodiment of the present invention.

FIGS. 5a and 5b are side section view drawings, respectively, of acartridge portion and a power supply portion of an electronic cigaretteaccording to an illustrative embodiment of the present invention.

FIG. 6 is a functional block diagram an electronic cigarette accordingto an illustrative embodiment of the present invention.

FIG. 7 is a detailed side section view drawing of a liquid reservoircartridge according to an illustrative embodiment of the presentinvention.

FIG. 8 is an exploded view drawing of a liquid reservoir cartridgeaccording to an illustrative embodiment of the present invention.

FIG. 9 is a partially exploded section view drawing of a liquidreservoir cartridge according to an illustrative embodiment of thepresent invention.

FIG. 10 is a section view drawing of a liquid reservoir cartridgeaccording to an illustrative embodiment of the present invention.

FIG. 11a, 11b , 11 c, and 11 d are a first end view, a first sidesection view, a second end view, and a second side section view drawing,respectively, of an atomizing assembly according to an illustrativeembodiment of the present invention.

FIGS. 12a, 12b, and 12c are a first end view, a side section view, and asecond end view drawing, respectively, of an atomizing chamber accordingto an illustrative embodiment of the present invention.

FIGS. 13a, 13b, and 13c are a first end view, a side section view, and asecond end view drawing, respectively, of a mouthpiece housing accordingto an illustrative embodiment of the present invention.

DESCRIPTION OF THE INVENTION

Illustrative embodiments and exemplary applications will now bedescribed with reference to the accompanying drawings to disclose theadvantageous teachings of the present invention.

While the present invention is described herein with reference toillustrative embodiments for particular applications, it should beunderstood that the invention is not limited thereto. Those havingordinary skill in the art and access to the teachings provided hereinwill recognize additional modifications, applications, and embodimentswithin the scope hereof and additional fields in which the presentinvention would be of significant utility.

In considering the detailed embodiments of the present invention, itwill be observed that the present invention resides primarily incombinations of steps to accomplish various methods or components toform various apparatus and systems. Accordingly, the apparatus andsystem components and method steps have been represented whereappropriate by conventional symbols in the drawings, showing only thosespecific details that are pertinent to understanding the presentinvention so as not to obscure the disclosure with details that will bereadily apparent to those of ordinary skill in the art having thebenefit of the disclosures contained herein.

In this disclosure, relational terms such as first and second, top andbottom, upper and lower, and the like may be used solely to distinguishone entity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions. The terms “comprises,” “comprising,” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises a list ofelements does not include only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. An element proceeded by “comprises a” does not,without more constraints, preclude the existence of additional identicalelements in the process, method, article, or apparatus that comprisesthe element.

The present invention advances the art of electronic cigarettes byteaching an electronic cigarette that provides a liquid reservoir, whicheffectively delivers liquid at the requisite rates from the reservoir toan atomizer in a open atomizing chamber. This arrangement enablesproduction of aerosol of the liquid at desired rates of atomizationwithout excessive liquid transfer during periods of non-use. Thisfunction is enabled though utilization of a wick aperture through theatomizing chamber and a wick disposed between the liquid reservoir andthe atomizer. The wick enables the transfer of liquid by capillarity ina controlled manner without flooding the open atomization chamber.

Reference is directed to FIG. 1 is a perspective view drawing of anelectronic cigarette 2 according to an illustrative embodiment of thepresent invention. The electronic cigarette 2 comprises a housing havinga first elongated portion 10 and a second elongated portion 12. Thesecond elongated portion 12, also referred to as the “cartridge” incertain illustrative embodiments, comprises a mouthpiece end 4, whichhas an aerosol outlet (not shown) for drawing air through the cartridge12. The first elongated portion 10 and the second elongated portion 12are removable joined together with a mechanical coupler 14. One or moreair inlet vents 16 are provided about the coupler 14 for allowingairflow into the cartridge 12 when the user draws air through theelectronic cigarette 2. The first elongated portion 10 comprises a tipend 6, which in the illustrative embodiment, is fabricated from atranslucent material enabling the transmission of light therethrough.Within the second elongated portion 12 is disposed a liquid reservoir(not fully shown). The liquid reservoir includes a clear or translucentwindow 13 to the exterior of the housing 12 for visually determining theliquid level 15 within the liquid reservoir.

Now, considering FIGS. 2a, 2b, and 2c , these are a tip end view, a sideview, and mouthpiece end view, respectively, drawing of an electroniccigarette according to an illustrative embodiment of the presentinvention. Note that the first elongated portion 10 and second elongatedportion 12 combine at coupler 14 to present a complete electroniccigarette 2 that closely resembles a tobacco cigarette. The cartridge 12is fabricated with a finished material resembling the filter of atobacco cigarette, and the first elongated portion 10 is fabricated toresemble the tobacco roll of a tobacco cigarette. As noted above, thecartridge 12 includes a window 13 for visually determining the liquidlevel of the internal liquid reservoir (not shown). The mouthpiece end 4includes an aerosol outlet opening 5, for drawing air and aerosol out ofthe cartridge 12. Air is inlet to the electronic cigarette 2 at the ventopenings 16 located at the coupler 14. The air inlet openings 16 can belocated elsewhere on the electronic cigarette 2, and is a matter ofdesign choice. In the illustrative embodiment, the tip end 6 is atranslucent gray material resembling an ash.

Reference is directed to FIGS. 3a and 3b , which are side view drawings,respectively, of a cartridge portion 12 and a power supply portion 10 ofan electronic cigarette according to an illustrative embodiment of thepresent invention. A threaded extension 20 on the power supply portion10 of the housing threadably engages the mechanical coupler 14 on thecartridge portion 12. In addition, as will be described more fullyhereinafter, an electrical connection is also facilitated in theconnection between the threaded extension 20 and the mechanical coupler14. The cartridge portion 12 can thusly be installed, uninstalled, andreplaced as needed. The cartridge portion contains the liquid reservoirand the window 13 provides the visual cue as to the liquid remaining Thetip end 4 can be removed in certain illustrative embodiments tofacilitate the addition of liquid to the reservoir. The tip end 6 glowby light of an internal amber LED in response to suction pressure at theaerosol outlet 5.

Reference is directed to FIGS. 4a, 4b, and 4c , which are tip end view,side section view, and mouthpiece end view, respectively, drawings of anelectronic cigarette according to an illustrative embodiment of thepresent invention. Reference is additionally directed to FIGS. 5a and 5b, which are side section view drawings, respectively, of a cartridgeportion and a power supply portion of an electronic cigarette correspondto this illustrative embodiment. FIGS. 4 and 5 correspond to the sameillustrative embodiment and provide details of the internal structuresof the illustrative embodiment. The tip end 4 is a resilient insert thatengages the interior of the cartridge housing 12 and provides theaerosol outlet 5, which is a passage formed therethrough. Within thecartridge housing 12 is an atomizing chamber 38 that has an open chimney36 extending to the aerosol outlet 5. The chimney 36 is located withinthe cartridge housing by a resilient seal 42. The annular space formedbetween the interior of the cartridge housing 12 and the chimney 36defines the liquid reservoir 43. At the upper end, resilient seal 42closes and seals the liquid reservoir 43. The lower end of the reservoir43 engages the atomizer assembly 28, which will be more fully describedhereinafter.

In FIGS. 4 and 5, the atomizer assembly 28 include the atomizer 32,which is disposed within the atomizer chamber 38. In addition, theatomizer assembly 28 comprises the mechanical coupler 14 that engagesthe threaded extension 20 of the power supply portion 10. Within themechanical coupler 14, and also a part of the atomizer assembly 28, isan electrical coupler 22 that has an air inlet port 26 formedtherethrough, which is pneumatically coupled into the atomizing chamber38. Thusly, the pathway for the flow of fresh air in and aerosol outincludes air drawn through the mechanical coupler 14, through the airinlet port 26, to the atomizer 32 within the atomizing chamber 38, upthe chimney 36 and out the aerosol outlet 5.

In FIGS. 4 and 5, the power supply portion 10 of the housing has athreaded extension 20 that engages the mechanical coupler 14. There isalso a corresponding electrical connection such that the power supplyportion 10 can deliver electric current to the atomizer 32 to facilitategeneration of aerosol. Two conductors are provided, including the outermechanical connection and the central pneumatic/electric connection.Suitable milling for air-flow channels is provided to facilitate solidmechanical, conductive electrical, and pneumatic connections. In theillustrative embodiment, power is derived from a storage battery 11. Apressure sensor 48 detects negative pressure within the housing 10 andenergizes the atomizer. The pressure sensor 46 is located by a pressureseal 50. A draw circuit 52 provides the electrical operation functions.In addition, and amber LED 54 is disposed to illuminate through thetranslucent tip 6 to emulate burning ash while the draw pressure sensor48 detects negative pressure.

Reference is directed to FIG. 6, which is a functional block diagram anelectronic cigarette according to an illustrative embodiment of thepresent invention. This diagram presents the electrical functions of theelectronic cigarette. The battery 60 provides power to a draw circuit70. A pressure sensor 68 is disposed within the cigarette housing 68.When negative pressure is detected, the draw circuit 70 deliverselectric power to the atomizer 64 and the amber LED 72. This actioncauses aerosol to be produced in the presence of the negative pressure,and the tip of the electronic cigarette to glow amber so long as thenegative pressure continues. The atomizer 64 is electrically coupled tothe circuit through electrical coupler 62.

Reference is directed to FIG. 7, which is a detailed side section viewdrawing of a liquid reservoir cartridge according to an illustrativeembodiment of the present invention. This drawing provides furtherdetails into the structure and operation of the liquid reservoircartridge assembly. The cartridge comprises an outer housing 12 that isclosed at the upper end by the tip end resilient insert 4, which has theaerosol port 5 formed therethrough. The lower end of the housing 12 isclosed with the atomizer assembly 28, which has the mechanical coupler14 at the extreme end. Plural air inlet vents 16 are formed though themechanical coupler so that fresh air can enter while it is secured tothe power supply housing. Within the cartridge housing 12 is theatomizing chamber 38 that is pneumatically coupled to the chimney 36,which is aligned with the aerosol outlet 5. The chimney 36 is locatedand sealed at the upper end by resilient seal 42. The annular space 43between the chimney 36 and the interior of the housing 12 defines theliquid reservoir 43. Note that there is a thinner annular cavity 39formed between the exterior of the atomizing chamber 38 and interior ofthe cartridge housing 12. The fluid 44 is stored in the fluid reservoir43, and is also capable of flowing into the annular cavity 39 tosaturate wick 37.

In FIG. 7, the atomizing assembly 28 is comprised of several components.The atomizer 32 is a coiled nickel-chromium heater through which thewick 37 passes. The wick 37 passes through wick apertures in theatomizing chamber (not shown) on its two ends, and into the annularcavity 39. The atomizer assembly 28 is machined from a suitable metaland includes the mechanical couple 14, the electrical coupler 22, whichis supported by an insulative support 24, and which has the air inletport 26 formed therethrough. During operation, when there is a negativepressure imposed on the system by drawing air out of the aerosol outlet5, and while electric current is delivered to the atomizer 36, airenters the air inlet port 26 and carries aerosol of the liquid 46 awayfrom the atomizer 32, up the chimney 36 and out the aerosol outlet 5. Asthe liquid in the wick 37 is depleted by the atomizer 32, capillaryaction draws additional liquid from the liquid reservoir 43, through thecavity 39 and to the atomizer 32.

Reference is directed to FIG. 8, which is an exploded view drawing of anatomizer 28, atomizing chamber 38, chimney 36 and resilient seal 42according to an illustrative embodiment of the present invention. In theillustrative embodiment, the atomizing chamber 38 and chimney 36 areformed as a single unit. The resilient seal 42 is a donut shapedpolymeric material that is pressed onto the upper end of the chimney 36.The atomizing chamber 38 includes a pair of opposing wick apertures 40formed therein, which provide clearance for the wick 37 to pass into theatomizing chamber 38. The atomizing assembly 28 includes the mechanicalcoupler 14 at its lower end and the atomizer 32 at its upper end. Thewick 37 passes through the center of the atomizer 32. The atomizingassembly has a pair of semicircular recesses 30 formed therein whichalign cooperatively with the wick apertures 40 in the atomizing chamberwhen the two units are engaged. This results in a circular aperturethrough which the wick 37 passes with a slightly compressive fit. Thisarrangement enables liquid to pass through by capillarity of the wick37, but prevents the liquid from flooding the atomizing chamber 38,which would be detrimental or atomizer function.

Reference is directed to FIG. 9, which is a partially exploded sidesection view drawing, and to FIG. 10, which is an assembled side sectionview drawing, of a liquid reservoir cartridge according to anillustrative embodiment of the present invention. The wick 37 passesthrough the atomizer 32 and extends to the outer periphery of theatomizer assembly 28. The atomizing chamber 38 is engaged with theatomizing assembly 28, thereby perfecting the wick aperture 40 asdescribed hereinbefore, and enclosing the atomizing chamber 38. Theresilient seal 42 is disposed between the exterior of the chimney 36 andthe interior of the housing 12, thereby sealing the upper end of thefluid reservoir 43. The tip end resilient insert 4, with the aerosoloutlet port 5, closes the upper end of the cartridge housing 12, and thechimney 36 is thereby aligned and sealed to the aerosol outlet 5. Thehousing 12 is engaged with the atomizer assembly 28, which urges theends of the wick 37 downwardly and constrains them within the annularcavity 39 formed between the interior of the housing 12 and the exteriorof the atomizing chamber 38. The wick 37 is thusly enabled to absorb theliquid (not shown). The atomizer 32 has a first end electrically coupledto the atomizer assembly body 28 and a second end electrically coupledto the electrical coupler 22. The electrical circuit is completed whenthe cartridge is engaged with the power supply portion, discussedhereinbefore. The atomizing chamber 38 is thusly sealed but for theentry of fresh air through air inlet port 26 and the exit of air andaerosol up chimney 36 and out aerosol outlet 5.

Reference is directed to FIGS. 11a, 11b . 11 c, and 11 d, which are afirst end view, a first side section view, a second end view, and asecond side section view drawing, respectively, of an atomizing assembly28 according to an illustrative embodiment of the present invention. Theassembly is based on a metal body 28 that has a electrical coupler 22insulatively supported 24 therein. The electrical coupler 22 has an airinlet port formed therethrough. The electrical coupler has a pair of airrecesses 27 machined on its face so that an air channel is created whenthe cartridge is engaged with the power supply portion of the electroniccigarette. In this manner, the air path is from the exterior, throughthe air inlet vents 16, through the air recesses 27, through the airinlet port 26 of the electrical coupler and u to the atomizer 32. Thewick 37 is positioned through the central cavity of the atomizer 32 andextends through the pair of semicircular recesses 30 in the body 28. Thewick is a fibrous bundle, which is formed from a temperature resistantmaterial, and may be selected from amongst aramid, fluorocarbon,sulfide, melamine, polyimide, carbon, and glass fibers. Or, from othersuitable materials known to those skilled in the art.

Reference is directed to FIGS. 12a, 12b, and 12c , which are a first endview, a side section view, and a second end view drawing, respectively,of an atomizing chamber 38 and chimney 6 according to an illustrativeembodiment of the present invention. In the illustrative embodiment, theatomizing chamber 38 and chimney 36 are formed as a single unit. Theatomizing chamber 38 and the chimney 36 are cylindrical in form. Theresilient seal 42 is a donut shaped polymeric material that is pressedonto the upper end of the chimney 36. The atomizing chamber 38 includesa pair of opposing wick apertures 40 formed therein, which provideclearance for the wick (not shown) to pass into the atomizing chamber38.

Reference is directed to FIGS. 13a, 13b, and 13c , which are a first endview, a side section view, and a second end view drawing, respectively,of a mouthpiece housing 12 according to an illustrative embodiment ofthe present invention. The housing 12 is a cylindrical plastic tube inthe illustrative embodiment. The plastic is transparent or translucentto facilitate visual inspection of the liquid content. The tip endresilient insert 4, with the aerosol outlet port 5, closes the upper endof the cartridge housing 12.

Thus, the present invention has been described herein with reference toa particular embodiment for a particular application. Those havingordinary skill in the art and access to the present teachings willrecognize additional modifications, applications and embodiments withinthe scope thereof.

It is therefore intended by the appended claims to cover any and allsuch applications, modifications and embodiments within the scope of thepresent invention.

What is claimed is:
 1. An electronic cigarette cartridge apparatus,comprising: a housing having a mouthpiece with an aerosol outlet; anatomizer disposed within an atomizing chamber, and operable toselectively generate an aerosol of the liquid in response to electriccurrent flowing therethrough; said atomizing chamber having an airinlet, an atomizer outlet coupled to said aerosol outlet, and a firstwick aperture; a liquid reservoir disposed within said housing andsealably separated from said atomizing chamber, and a wick disposedthrough said first wick aperture between said liquid reservoir and saidatomizing chamber and configured to transfer the liquid by capillarityfrom said liquid reservoir to said atomizer; wherein said atomizeroutlet and said aerosol outlet are coupled by a chimney.
 2. Theapparatus of claim 1, further comprising: an inlet vent formed on theexterior of said housing and coupled to deliver air to said atomizingchamber air inlet.
 3. The apparatus of claim 2, and wherein said inletvent is coupled to said atomizing chamber air inlet by a conduit.
 4. Theapparatus of claim 3, and wherein said conduit sealably passes throughsaid liquid reservoir.
 5. The apparatus of claim 1, and wherein saidchimney sealably passes through said liquid reservoir.
 6. The apparatusof claim 1, and wherein said atomizer is a resistive heating element. 7.The apparatus of claim 6, and wherein said wick is partially engagessaid resistive heating element.
 8. The apparatus of claim 1, and whereinsaid atomizer has a tubular form defining an open central passage. 9.The apparatus of claim 8, and wherein said wick passes through said opencentral passage.
 10. The apparatus of claim 1, and wherein saidatomizing chamber further comprises a second wick aperture, and whereina first end of said wick passes through said first wick aperture and asecond end of said wick passes through said second wick aperture. 11.The apparatus of claim 1, and wherein said wick is fabricated as abundle of heat resistant fibers.
 12. The apparatus of claim 11, andwherein said bundle of heat resistant fibers is fiberglass.
 13. Theapparatus of claim 11, and wherein said bundle of heat resistant fibersis fabricated from a material selected from; aramid, fluorocarbon,sulfide, melamine, polyimide, carbon, and glass.
 14. The apparatus ofclaim 1, and wherein said liquid reservoir is formed as an annularcavity between the interior of said housing and said atomizing chamber.15. The apparatus of claim 1, and wherein said liquid reservoir includesan external access opening, for enabling addition of liquid into saidliquid reservoir.
 16. The apparatus of claim 15, and wherein saidexternal access opening is a removable mouthpiece.